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Numerical simulation of convex shape beam spot on stress field of plasma-sprayed MCrAlY coating during laser cladding process

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A Correction to this article was published on 09 November 2021

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Abstract

To reduce the thermal stress at the clad layer and further reduce the crack generation in the laser cladding process, a method of controlling the cracks at the clad layer by changing the laser energy density is proposed. Comparative thermal–mechanical coupling finite element analysis was performed on the uniform rectangular and convex shape beam spot cladding processes on plasma-sprayed MCrAlY coating through the numerical simulation method based on the ANSYS software. Results show that rapid heating and cooling characteristics, which are typical in laser processing, are manifested in the cladding process using a uniform rectangular spot, whereas a convex shape spot can exert preheating and slow cooling effects to a certain extent, thereby reducing the temperature gradient of the cladding and non-cladding zones. In addition, on the precondition of equivalent cladding effect, the thermal stress at the clad layer is also low, enabling the effective mitigation of the cracking tendency of the clad layer. Relative to the laser beam-shaped diffractive optical element special for design and manufacturing, superposing two uniform rectangular spots with different sizes and energy densities is a simpler and more effective method of obtaining a convex shape spot.

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Funding

The authors received funding from the Anhui Provincial Natural Science Foundation (Grant No. 2008085ME149), Anhui Provincial Top Academic Aid Program for Discipline (Major) Talents of Higher Education Institutions (Grant No. gxbjZD2020087), Anhui Provincial Natural Science Research Key Program of Higher Education Institutions (Grant No. KJ2020A0693, KJ2020A0700, KJ2018A0479, KJ2015A197), Key Research and Development Project of Tongling City (Grant No. 20200201010), Anhui Provincial Excellent Young Talents Fund Key Program of Higher Education Institutions (Grant No. gxyqZD2016320), Anhui Provincial Excellent Young Talents Fund Domestic Visiting and Study Program of Higher Education Institutions (Grant No. gxgnfx2020101), Academic Leader and Backup Candidate Research Project of Tongling University (Grant No. 2020tlxyxs02, 2020tlxyxs04), and Anhui Provincial University Student Innovation and Entrepreneurship Training Programs (Grant No. s202010383119).

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Authors and Affiliations

  1. College of Mechanical Engineering, Tongling University, Tongling, 244000, China

    Peipei Zhang, Jiaqing Chu, Guang Qu & Dongsheng Wang

  2. Key Laboratory of Construction Hydraulic Robots of Anhui Higher Education Institutes, Tongling, 244000, China

    Dongsheng Wang

  3. Key Laboratory of Additive Manufacturing of Tongling City, Tongling, 244000, China

    Dongsheng Wang

  4. Engineering Technology Research Center of Semiconductor Packaging Die of Tongling City, Tongling Yuanyi Precision Machinery Co., Ltd, Tongling, 244000, China

    Dongsheng Wang

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  1. Peipei Zhang
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  3. Guang Qu
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  4. Dongsheng Wang
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Methodology: Peipei Zhang and Dongsheng Wang; data curation: Jiaqing Chu and Guang Qu; writing—original draft preparation: Peipei Zhang and Dongsheng Wang.

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Correspondence to Dongsheng Wang.

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Zhang, P., Chu, J., Qu, G. et al. Numerical simulation of convex shape beam spot on stress field of plasma-sprayed MCrAlY coating during laser cladding process. Int J Adv Manuf Technol 118, 207–217 (2022). https://doi.org/10.1007/s00170-021-07949-9

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